Coil structure for transformers and the like.



C. H. THORDARSON.

COIL STRUCTURE FOR TRANSFORMERS AND THE LIKE.

APPLICATION FILED APR. 23. 191'7.

Patented Feb. 12, 1918.

1722/6 nior- 1 arddmon CHESTER H. THQRDARSON, (Jli CHICAGO, ILLINOIS.

COIL STRUCTURE FOR TRANSFORMERS AND THE LIKE.

Specification of Letters Patent.

Patented Feb. 12., 1918..

Original application filed July 10, 1915, Serial No. 39,044. Divided and this application filed April 23, 1917.

Serial bio-163,868.

To all whom it may concern:

Be it known that I, Ci-rnsrun H. TnononnsoN. a citizen of the United States, and a resident of Chicago, in the county of Cook and State of Illinois, have invented certain new and useful Improvements in Coil Structures for Transformers and the like; and I do hereby declare that the following is a full, clear, and exact description thereof, reference being had to the accompanying drawings, and to the characters of reference marked thereon, which form a part of this specification.

This invention relates to a novelwinding coil structure of the pancake or disk type, and is adapted more especially to that type of winding coil which is made up of a spirally wound flat wire, such, for instance, as is shown in my prior application for U. S. Letters Patent Serial'No. 3994A, filed July 10, 1915, of which the application is a division.

Airong the objects of the present invention i to mechanically strengthen the units or coils so that they may. be individually handled without danger of collapsing them and to strengthen them in the assembled transformers or other electromagnetic devices.

A further object of the invention is to provide, in connection with a winding unit which is thus made up of flat bare Wires with 'the turns insulated by one or more strips of insulating material, means whereby the thin fiat. wires may be joined to relatively heavier wires or conductors at the inner side of the coil which relatively heavier wires are provided in order to mechanically strengthen ihe coil structure.

Another object of the invention is to provide a novel means of uniting the innermost turn of the coil in such a way as to produce a still mechanical union and to insulate one end of the turn from the other end thereof.

Other objects of the invention are to improve and simplify coil structures of this character, and the invention consists in the combination and arrangement of the parts shown in the drawings and described in the specification, and is pointed out in the appended claims.

In the drawings F igure 1 is a face view of a Winding coil or unit embodying my invention.

.main body of said unit.

2 is a section on the line 2% of F l.

l 3 is a detail of the insulating joint between the ends of the inner stiilening turn shown in Fig. l.

As shown in said drawin s, the coil 10 is made up principally of a spirally wound flat wire comprising a plurality of turns ll that are spaced by suitable insulating material 1%, such, for instance, as one or more sheets or paper.

in order to stiffen the coil structure, the inner and outer turns 14, 15, respectively, are made of relatively heavier wire, the inner tnrn 14; being of relatively larger cross section than the outer turn and sui'liciently massive to afford the desired rigidity at the inner side of the coil structure. As herein shown the innermost turn ll consists oia halt round cross section ith the flattened side thereof lying against and in metal to metal contact with the next adjacent fiat turn. The first i ew turns 16 of the conductors are preferably made thicker than the turns ll which make up the principal part of the coil structure, and by reason of the small potential difference between said turns, the insulation 17 need not be so great as between the turns toward the outer side of the coil.

he thin wire which constitutes the principal portion of the coil structure is preferably joined to the heavier wire 16 by means not requiring solder, it not being practicable to solder the thin wire.

The present method is best shown in Fig. 2, and it consists, at the inner part of the unit, of laying on the flat face of the outer heavier turn 16, and for a substantial length therealong and in metal to metal contact with the outer turn 16 the innermost end of the thin fiat wire 11 which composes the The thin and thicker liat wire in metal to metal contact produce a reliable electrical contact without other fastening means; the inner stiffening connecting turns being held assembled by pressure due to the winding of the wire.

The inner turn 14 may be fastened together at its ends by means of an insulating dowel 18 the ends of which enter sockets formed in the ends of the inner turn, and said dowel is provided between its ends with a flange 19, which bears against the fiat ends of the inner turn to prevent short circuiting about the inner turn. The said flanged dowel also provides an amply rigid connection between the ends of the inner turn.

The outer stiffening turn is made of such thickness that it acts by its own resiliency to hold the thinner wire of the coil structure from unwinding.

I claim as my invention 1- 1. A winding unit composed of a spirally wound, fiat wire with an insulating medium between the turns thereof, the inner and outer turns of the unit being of large cross section to mechanically stiffen the unit.

2. A winding unit composed of a spirally wound, flat wire with an insulating medium between the turns thereof, the inner turn of the unit comprising a stiff wire to brace the winding and means for electrically eonnectingthe inner turn of thin wire of the unit to the bracing turn comprising a few turns of flat wire of intermediate thickness, with the turns insulated from each other laid at one end against the stiffening turn in metal-to-metal contact and laid at the other end thereof in metal-to-metal contact against the inner end of the thinner wire of the winding.

3. A winding unit composed of a spirally wound fiat wire with an insulating medium between the turns thereof, the inner turn of the unit being of large cross section to mechanically stitfen the unit, and electrically connected to the thin wire, and an insulating and connecting ClQYlCB between the ends of the said inner turn.

4. A winding unit composed of a spirally wound fiat wire with an insulating medium between the turns thereof, the inner turn of the unit being of large cross section to mechanically stiffen the unit, and electrically connected to the thin wire, the ends of said inner turn being provided with openings and a dowel seated in said openings to mechanically connect the said ends and provided with an insulating barrier to electrically insulate said ends from each other.

5. A winding unit composed of a spirally wound flat wire with an insulating medium between the turns thereof, the inner turn of the unit being of large cross section to mechanically stiffen the unit.

6. A winding unit composed of a. spirally wound flat thin wire, with an insulating medium between the turns thereof, the outer turn of the winding comprising a wire including somewhat less than a complete circle and of a cross section and stilfness to mechanically brace the winding and prevent unwinding of the thinner turns.

In witness whereof I claim the foregoing a my invention, I hereunto append my signature in the presence of two witnesses at Chicago, Illinois, thi 19th day of March,

CHESTER H. THORDARSON. Witnesses:

W. L. HALL,

G. A. SOUTHWELL. 

